O843K Pages 1-28 05/03
Contents
1. SALON 4 0SZ 0 2 002 330N3S i8 59 0 Ore dl q 97199 1 HOLIMS f dN31 3NI9N3 EE rsa eT o Gss 08 0 jo M30N3S 08 3n8 SVG 3HnSS3Nd Tow d HOLIMS ow 38155384 10 4 2078 9N3 xod KE 3802 T sore 2 us ____ _ _ rm lt HOLWS 15 1339 u 86 S 8e 3LIHM AvE gION310S Ove 13 14 quu 35 Z 3l 80d AVIS Nl E ois 1 PN 70681 7 50 WHM Oif ele od 1 319804 2 una 12 24 a ec 1 lt 2 I r L_ O SOLVOIGNI J M 2 le 7 59014 1 u 3 4 E 387133 OF 66 1 038 734 all 8 1380 766 g 668 1 I g gt gt I gt O lt HOLIMS 2 8 8 wx SSVdA8B vel lt le HSNVAS NMOQLNHS 9 CaF a oF oor oF s 2 v q38 M0TI3A 61 5 HOLIMS 5 JOMINOO 3NION3 18698098 333338 7 No lt UNYI INIS 301 Hov3 14 S lt TP Ol HI9N31 O3 201 201 31BVO 1 OMY V d 20 Ati 4 S3SS3NNVH NI 319201 8 5 m INIONG lt AV 13s NOISN31X3 lt I3NVd2. iring W O843K 05 03 26 Grc19 g Surwe1q Dd ATI MNEP8IN SULM 7 E D lt nid SSINYYH Ond SS3NuVH wove NY Qa 3015 3NION3 3015 E s Eo SOT TAT NWT ZA E Fei un 1 k Nu p gi NONI N I 25 a ataqa ot askai SOT TIT 308771 K_A b a DNL rsd 08 1300 7 potum M nr 101 Be I TN 4 21 INIOd NOILO3NNOO H2V3 YIMYYW 3MIM AB 03 41 301 38 1SnW sawna S A349 38 OL SYOLONGNOD Q3TIVISNI 3 0 V TW 03009 30102 5531 0 2 fer see 38898 O310N SV 1d32X3 OvAO09 x4 GNVULSILINN 2 601 MLW 1 OMY 38 01 SHOLONGNOD NOLIVTIVISNI TIV 1 527071 x CE CLIE pm I 53 0 i s s Fi I pee Picasa On ER EA IESU ERA RR 77 1935 1 eas fo m NETS HOLMS X5vi8 o ANA SSYdAg ass j NIS NMOGLNHS _ x5 G35 MOTTE HOLIMS T Sd g IQBINOO ANIONI XO 3052 0 18 WL d 934 s AWNOILdO 1 0 35 sng AAU NAA 3wns jud o _ XoviB 11 4 10 1 09 59 08 38 T
3. Remove the return line Figure 14 Unscrew and remove the injectors Figure 15 NOTE Do not use pry bars to remove injectors from cylinder head After removing the injectors discard the copper sealing washers from the injector hole in the head Figure 16 Cover holes to prevent dirt and debris from entering the cylinders f Injector installation a Install a new copper sealing washer in each injector hole Figure 16 Screw in injector and tighten to 44 51 ft Ibs 6 to 7 kgm Figure 17 NOTE Overtightening can damage injector Install return line using a new sealing washer b below each connection Tighten return line retaining bolts to 22 30 ft Ibs Install delivery lines Leave loose at injectors for bleeding Crank engine to fill lines Tighten lines at injectors to 11 18 ft Ibs Start engine and check for leaks using a piece of paper or cardboard DO NOT use hand to check for leaks SP12 INJECTION PUMP Since operating conditions may vary considerably it 18 difficult to give a definite interval for checking the injection pump But as a rule pump settings maximum speed idle speed and exhaust smoke should be checked after every 2400 hours of operation Service of the fuel injection pump should only be done if checks indicate pump malfunction Black smoke can be an indication of pump malfunction Before servicing the pump check other possible causes a Check cleanliness of air filter b
4. Check valve clearances c Clean and check injectors Any repair which involves disassembly of the injection pump must be carried out by specially trained mechanics with the proper tools and test equipment NOTE All warranties on the engine become null and void if the injection pump seals are broken by unauthorized persons COOLING SYSTEM GENERAL NOTE Marine sets be sure to close the sea cock before working on the engine cooling system CAUTION The cooling water in the engine reaches extremely high temperatures You must use extreme caution when working on hot engines to avoid burns Allow the engine to cool before working on the cooling system Open the filler cap carefully using protective clothing when the engine is warm SP13 CHECK THE COOLANT LEVEL 1 Check the coolant level each day before starting the engine Check the water level by removing the pressure cap from the expansion tank In order to give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler cap sealing surface when the engine is cold The pressure valve in the filler cap releases when the pressure is approximately 7 PSI 0 5 bar Use a cap pressure tester to check cap if you suspect it is faulty O843K 05 03 17 4 Flush the cooling system every 600 hours or every 12 months whichever comes first Marine sets a Remove expansion tank cap and drain engine block b Open block d
5. 35 10 kW 1500 50Hz Inline 3 91 in 1 5 L 4 3 3 x 3 54 in 84 x 90 mm counter clockwise 22 1 5 8 gal 5 5 liter Natural SAE 4 C 107 16 6 HP 700 Ibs 318 kg 36 6 in 1078 mm 19 3 in 490 mm 24 7 in 627 mm 1 1 gal 4 1 liters 3 4 in 19 mm 3 4 in 19 mm 3 4 in 19 mm 658 BTU min 11 0 gal min 42 Itr min 7 7 gal min 29 Itr min 39 in 1M 4 feet 1 2 M 1 in 25 4 mm 1 25 in 31 75 mm 120 Amp Hour 1 12 Volt 1 Phase Std 3 Phase Opt 33 cfm 95 M m 48 in 1219 mm H O 2 in 51 mm 96 cfm 7 7 1022 F 550 C 5 16 3125 in 7 9 mm 5 16 3125 in 7 9 mm 39 in 990 mm 423 Ibs hp hr 99 US gal hr Left Down Right Down 0 23 0 23 0 35 0 35 0843 05 03 25 6 9 3UIMEXQ ATI ZULM SUA f a g m V op um Mis C MU SEEN LNIOd NOLIO3NNOO HOV3 LV 38333VW YSENNN AG JANIA 38 LSNW A3H9 38 OL SYOLINGNOD QG3TIVISNI Fay TV 03002 30102 5531 0 Z 0310 Sv ONY 030131 5 GSLSIML 143 3 ONVMISILTQW O GOL MLN pL SMV Ol SHOL9nO0NDO NDIIVTIVISNI TV L
6. Northern Lights marine generator set Model number of engine block Additional letter Bore Cylinders designates series NL Northern Lights industrial generator set 84 mm 3 within model number Northern Lights marine diesel generator set with Northern Lights industrial generator set with an N M843JK a J series 843 engine and a PX 300K generator end L843NK series 843 engine PX 300K generator with an AVR with an AVR and a radiator M843NK Northern Lights marine diesel generator set with an N series 843 engine and a PX 300K generator end O843K 05 03 2 Serial Numbers Your set has three serial numbers an engine number stamped on the block a generator plate and 9 a generator set plate e Serial No Model No aN ALASKA DIESEL ELECTRIC Inc 54957 4420 14TH AVE NW SEATTLE WA U S A NORTHERN LIGHTS Figure 1 Generator set serial number plate A warranty registration certificate is supplied with your set It entitles the original purchaser of our equipment to a warranty covering material or assembly faults The extent of coverage is described in the Limited Warranty Statement We recommend that you study the statement carefully Fill in the serial number of your unit in the box provided Use the serial number on the generator set plate when ordering parts or in correspondence The generator set plate is found on the service side of the generator and resembles the drawing in
7. System General M843JK and M843NK Marine Generator 4 Cooling System Flushing NL843NK Industrial Generator 5 Heat Exchanger Marine Raw Water Pump CONTROL PANELS Generator Ends Northern Lights Generator Sets 6 7 Electrical System General Glow Plugs enters OPERATING PROCEDURES Booster Batteries Break in Beriod ie eet evo eso 8 Battery Care mter Before Starting a aiie 8 PTO Staring 8 Winterizing Out of Service Operati naa aksuta asahan 8 Exhaust Elbow Siena 8 Shutdowns and Alarms eee 9 TROUBLESHOOTING Spare Parts ses 22232 5 2 9 Electrical isas au agua EnBgln6e ueteri SERVICING SCHEDULE CHART 10 11 DATA SHEETS SERVICING MS843JK Lubrication General sees 12 M843NK erre ens Checking tee erit rS RS 12 Oil Changes iini 12 WIRING DIAGRAMS Changing Oil Filter eee 12 DC Electrical eto Air eee ir ERR RIS 13 Proprietary Information This publication is the property of Alaska Diesel Electric Inc It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric Inc Alask
8. after applying engine oil to gasket surface Screw on until the gasket surface comes into contact with sealing surface of filter base Then tighten it two thirds of a turn by hand Do not overtighten b Fuel filter part numbers are 843JK and 843NK 130336020 O843K 05 03 14 SP10 BLEEDING THE FUEL SYSTEM CAUTION Escaping diesel fuel under pressure can penetrate skin causing serious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure be sure all connections are tight and lines pipes and hoses aren t damaged Fuel escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fuel see a doctor at once Serious infection or reaction can develop if proper medical treatment isn t administered immediately Figure 9 NL843NK Fuel System 1 The fuel system is self bleeding However any 3 Loosen bleed screw Pump hand primer system may need manual bleeding when until pure fuel no bubbles escapes Then tighten a A new fuel filter is installed bleed screw C b The engine has run out of fuel 4 Ifthe engine does not start after the above bleeding c The fuel lines injection pump or any other fuel process loosen a fuel line at the injector while system component has been removed and cranking the engine with the starter motor until pure insta
9. of each battery Repair or replace Battery is too small Battery cables are too small Replace battery if necessary If low fill cells with distilled water Hill with oil of appropriate viscosity Clean and tighten loose connections f breaker is tripped reset it Clean and tighten battery and harness plug connections Check specific gravity and electrolyte level of each battery If you cannot correct problems with these procedures see your Northern Lights dealer O843K 05 03 20 Troubleshooting ENGINE PROBLEM Engine Hard to Start or Will Not Start POSSIBLE CAUSE Improper starting procedure No fuel Low battery output Excessive resistance in starting circuit Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged primary fuel filter element Clogged secondary fuel filter element Dirty or faulty injection nozzles Engine Runs Irregularly or Stalls Frequently Below normal engine temperature Clogged primary fuel filter element Clogged secondary fuel filter element Water or dirt in the fuel system Dirty or faulty injection nozzles Air in fuel system Improper type of fuel Lack of Engine Power Intake air restriction Clogged primary fuel filter element Clogged secondary fuel filter element Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty
10. oil level must be in the waffled area on the stick Never allow the level to go below this area Follow the lubrication recommendations above SP2 OIL CHANGES Q9 tA 9 The set is delivered with special break in oil Change the engine oil and oil filter after 50 hours of operation Use Service CC 30 weight oil during the first 100 hours Change the oil and filter again at 100 hours using the oil recommended in the above diagram After this change oil and filter every 200 hours During intermittent cold weather operation change oil every 100 hours or six weeks whichever comes first Change oil at the end of each season and the beginning of each season Change oil when engine is warm Dispose of waste oil in an approved manner Never use a flushing oil Loosen the clamp on the oil change tube Remove cap Drain oil Replace the cap and tube Refill engine with recommended oil for the season 10 Engine capacity with new oil filter is 843JK and 843NK 5 8 quarts 5 5 liters SP3 CHANGING LUBE OIL FILTER Change the lube oil filter every 200 hours Use a filter wrench to remove old filter Dispose of filter in approved manner Make sure the gasket from the old filter is removed and discarded Clean mount face Spread a thin film of engine oil on the rubber gasket on the new filter and screw it on nipple until gasket meets the sealing surface Using hands only no wrench tighten filter one half tu
11. reconditioned 1 Hold the Shutdown Bypass Preheat switch in the engine are critical to its life and performance ON position for 10 to 20 seconds before starting a 2 Frequently check the engine temperature and oil cold engine Holding the switch too long can burn pressure gauges sets with Series 3 or 4 panels out the glow plugs This step is not necessary if the 3 Oil consumption is greater during break in as engine is already warm piston rings take time to seat 2 While holding the Shutdown Bypass Preheat switch 4 Break In Oil Changes Change engine oil and in the ON position push the Engine Control switch filter at 50 hours Change oil and filter again at to the START position 100 hours consult Lubricants section for oil 3 As soon as the engine starts release both switches Do not recommendation crank the starter for more than 20 seconds consecutively 5 Retighten head bolts at 50 hours see page 13 If the engine fails to start with the first attempt be sure that it has stopped completely before re engaging Operating Instructions 6 NOTE Excessive cranking of the starter on Marine Maintain at least a 75 load on your generator sets equipped with a water lift muffler can cause set for the first 100 hours If this is not possible engine damage If the engine does not start after three maintain no less than a 50 load to ensure proper 20 second cranks remove the impeller from the raw seating of the piston rings Vary the load to help wa
12. 16 3125 in 7 9 mm 5 16 3125 in 7 9 mm 39 in 990 mm 446 Ibs hp hr 1 1 US gal h Front Down Rear Down 0 0 10 0 35 0 35 8 kW 1500 50Hz Inline 3 81in 1 33 liters 4 3 3 x 3 2 in 84 x 80 mm counter clockwise 23 1 6 0 gal 5 7 liter Natural SAE 4 C 107 14 5 HP 662 Ibs 300 kg 36 6 in 1078 mm 19 3 in 490 mm 24 2 in 616 mm 1 1 gal 4 1 liter 3 4 in 19 mm 3 4 in 19 mm 3 4 in 19 mm 548 BTU min 11 0 gpm 42 Ipm 7 7 gpm 29 Ipm 39 in 1M 4 feet 1 2 M 1 in 25 4 mm 1 25 in 31 75 mm 120 Amp Hour 1 12 Volt 1 Phase Std 3 Phase Opt 29 3 cfm 84 M m 48 in 1219 mm 2 in 51 mm 86 cfm 2 4 M m 10229 550 C 5 16 3125 in 7 9 mm 5 16 3125 in 7 9 mm 39 in 990 mm 445 Ibs hp hr 91 US gal h Left Right Down 0 23 0 35 O843K 05 03 24 M843NK Data Kilowatt Rating Prime Rated RPM Frequency General Information Cylinders Displacement Cycles Bore x Stroke Rotation Facing Flywheel Compression Ratio Total Engine Oil Capacity including Oil Filter Aspiration Flywheel Housing Size Flywheel Drive Size Rated Flywheel HP Dry Weight w Heat Exchanger 1 Length Width Height Cooling System Approx Cooling Capacity Minimum Through Hull Diameter Sea Water Pump Inlet Hose ID Minimum Sea Water Discharge Heat Rejection to Jacket Coolant Fresh Water Pump Capacity Seawater Pump C
13. 5 Check V belt tension SP18 Check electrolyte in batteries 100 HOURS SP3 Change lubricating oil filters SP4 Check air cleaner SP16 Check and clean radiator EVERY 200 HOURS SP2 Change engine oil and filter SP8 Change primary filter element Racor SP9 Change secondary fuel filter SP21 Inspect condition of exhaust elbow EVERY 600 HOURS SP6 Check valve clearances SP11 Check injectors SP14 Check and flush cooling system SP17 Change impeller in raw water pump SP19 Check condition of batteries with hydrometer 2400 HOURS SP12 Check fuel injection pump SP15 Check and clean heat exchanger O843K 05 03 11 Temperature 4 LUBRICATION GENERAL Use only clean high quality lubricants stored in clean containers in a protected area These lubricants are acceptable a API Service CC CD CE single viscosity oils b API Service CC CD SF multi viscosity oils Use the proper weight oil for your average operation temperature Single Viscosity SAE 30W Air Multi Viscosity Above 32 F 0 C SAE 15 40W 10 to 32 F 28 to 0 C SAE 10 30W SAE 10W SAE 5W Figure 6 Lube Oils Below 10 F 23 C SAE 5 20W Some increase in oil consumption may be expected when SAE 5W and SAE 5 20W oils are used Check oil level frequently Never put additives or flushing oil in crankcase SP1 CHECKING OIL LEVEL Check the oil level in the crankcase with the dipstick The
14. 843 Head Torque Sequence Servicing Vie Valve Adjustment Screw Rocker Arm 4 0 008 in 0 200 mm Figure 8 Valve Adjustment SP6 VALVE CLEARANCES 1 Adjust valve clearance after first 50 hours of operation and every 600 hours thereafter 2 Valve adjustments should be done after the cylinder head bolts have been re tightened Engine should be cold and NOT running 3 Watch the valves while turning the engine over by hand Turn until the inlet valve starts to open and the exhaust valve starts to close the valves are rocking Then turn the crankshaft one more full turn and adjust the clearance on both valves for this cylinder 4 Loosen the lock nut and adjust the clearance between the rocker arm and valve guide of both the intake and exhaust valves with the adjustment screw Figure 8 Clearance on both intake and exhaust valves should be 0 008 in 0 2 mm 5 Repeat steps 3 and 4 for each cylinder Each set of valves must be adjusted individually 6 Replace the rocker arm cover Tighten cover nuts to 5 8 ft Ibs 0 8 2 3 kg m O843K 05 03 13 p Use only clean high quality fuels of the following specifications as defined by ASTM designation D975 for diesel fuels a Use grade no 2 diesel at ambient temperatures above freezing 32 F 0 C b Use grade no 1 at ambient temperatures below freezing and for all temperatures at an altitude o
15. CH Used to check each phase for load condition NOTE Always leave this switch in the ON position while the unit is running Figure 5 Series 7 0 through Series 7 6 Generator Control Panels 10 FREQUENCY METER HERTZ The frequency meter indicates alternator current 1 SHUTDOWN BYPASS SWITCH frequency 60 Hz 1200 or 1800 RPM or 50 Hz 1500 RPM Manual Start Panels S 7 1 and S 7 3 11 A C VOLTMETER Hold the switch in the START position until the engine is Shows the generator output voltage running NOTE Excessive cranking may cause engine damage 12 A C AMMETER After the engine starts release the switch and it will return Shows the generator load on each phase The phase is to the RUN position To stop the engine hold the switch in selected with the Ammeter Selector switch the STOP position Auto Start Panels S 7 0 S 7 2 S 7 4 S 7 5 and S 7 6 After the engine starts release the switch and it will return to the RUN position To stop the engine hold the switch in the STOP position 2 OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system 3 HOUR METER Keeps track of engine running time 4 ENGINE TEMPERATURE GAUGE Registers the temperature of the coolant 5 DC VOLTMETER When the engine is running the voltmeter indicates the voltage output of the alternator O843K 05 03 7 Operating Procedures BREAK IN PERIOD STARTING 1 The first 100 hours on a new or
16. Circuit Breaker 17 Oil Filter 3 Air Filter 11 Secondary Fuel Filter 18 Fuel Lift Pump 4 Starter 12 Crankcase Vent 19 Block Water Drain 5 DC Circuit Breaker 13 Lube Oil Fill 20 Dipstick 6 Generator Junction Box 14 Coolant Fill 7 Starter 15 Injection Pump O843K 05 03 5 PREHEAT amp SHUT GENERATOR DOWN BYPASS START GENERATOR HOURS TOTAL LJ Figure 4 B Series 3 Generator Control Panel Hertz 150 200 250 A C vours 300 Control Panel Shutdown Bypass And Preheat Switch ot overcrank Figure 4 C Series 4 Generator Control Panel 4 Hobbs foo 0E 4 R Series 4 Generator Set Control Panels SHUTDOWN BYPASS PREHEAT SWITCH Two functions are built into this switch the preheating of the engine and bypassing of the engine safety shutdown circuit Hold switch in the ON position 10 20 seconds before starting the engine and continue holding on during engine cranking Release the switch as soon as the engine is running Holding the switch on too long can burn out the heater element ENGINE CONTROL SWITCH To start the engine hold this switch in the START position until the engine is running NOTE Excessive cranking of marine sets equipped with water lift muffler systems can cause engine damage See page 10 After the engine starts release the switch and it will return to RUN position To stop the engin
17. Figure 1 My Northern Lights generator set SERIAL number is NOTE If the warranty is to apply the servicing instructions outlined in this manual must be followed If further information is needed please contact an authorized dealer or the factory Safety Rules CAUTION Accident reports show that careless use of engines causes a high percentage of accidents You can avoid accidents by observing these safety rules Study these rules carefully and enforce them on the job Never leave engine without proper security e Turn the coolant tank cap slowly to relieve pressure before removing Add coolant only when the engine is stopped and cool Mount a fire extinguisher near engine e Always disconnect the battery ground strap before making adjustments Operate engines in properly ventilated areas Keep trash and other objects away from engine Escaping fluids under pressure can penetrate your skin Use a piece of cardboard or wood not your hands to search for leaks Avoid wearing loose clothing without a belt when working around engines Donotoil or grease engine while it is running Use caution in handling fuel Never refuel a hot or running engine Do not smoke while filling fuel tank or servicing fuel system Keep your hands feet hair and clothing away from power driven parts Check for any loose electrical connections or faulty wiring Engines should be operated only by knowled
18. OPERATOR S MANUAL M843JK M843NK NL843NK TDOWN Byp OFF 2 2 NORTHERN LIGHTS CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm NORTHERN LIGHTS Northern Lights 4420 14th Avenue N W P O Box 70543 Seattle WA 98107 Tel 206 789 3880 Fax 206 782 5455 Copyright 2003 Alaska Diesel Electric Inc All rights reserved Northern Lights and the Northern Lights logo are trademarks of Alaska Diesel Electric Inc Printed in U S A PART NO O843K 05 03 OPERATOR S MANUAL for Models M843JK M843NK and NL843NK Read this operator s manual thoroughly before starting to operate your equipment This manual contains information you will need to run and service your new unit INTRODUCTION ctm 2 SERVICING continued Models Included sese 2 b T Model Numbers oi egt estere 2 Retightening Cylinder Head Bolts Serial Numbers cccccecsccessceceeseeeceeeeessneeeensaes 3 Valve Clearances Fuels General ns WARRANTY sese eee eem 3 Fuel Filters aet rette Bleeding the Fuel System SAFETY RULES 1 1 1 eee 3 Injector Service Injection Pump COMPONENT LOCATIONS Cooling
19. Use the Trouble Shooting Guide on page 22 to isolate the cause of the overheat CAUTION Do not remove the water fill cap of an overheated engine Escaping high temperature steam can cause severe burns Allow the engine to cool and then remove the cap slowly using protective clothing d Make repairs Restart your Marine set after the temperature gauge registers below 200 F 94 C e Watch the temperature gauge regularly and turn off the unit if the temperature rises above 205 F 96 C on Marine units Repeat troubleshooting 3 If shutdown is activated and the temperature gauge shows temperature within normal temperature range a Check the engine crankcase oil level b If the oil level is low fill with recommended lubricating oil and restart Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading 20 60 PSI after a few seconds of operation c If the oil level is normal DO NOT restart the engine Call your dealer for assistance SPARE PARTS 1 ADE recommends that you keep the following spare parts on hand for field service The parts are available from your local Northern Lights dealer Some marine models already have On Board Kits a handy box that contains the most common parts you will need 2 All owners should have the following spares a Primary and secondary fuel filter elements Oil filters Air filter Alternator belt Thermostat and gaskets Sea
20. a Diesel Electric Inc All rights reserved Litho U S A Publication number O843K 05 03 O843K 05 03 1 Introduction Servicing of marine engines and generator sets presents Failures can begin with minor problems that are unique problems In many cases boats cannot be moved overlooked and become amplified when not corrected to a repair facility Marine engines cannot be compared during routine maintenance to the servicing of automobiles trucks or even farm equipment Failures often occur in remote areas far As operator it is your obligation to learn about your from competent assistance Marine engines are taxed equipment and its proper maintenance This is not a far more severely than auto or truck engines therefore comprehensive technical service manual Nor will it maintenance schedules must be adhered to more make the reader into an expert mechanic Its aim is to strictly aid you in maintaining your unit properly Unit Identification MODELS INCLUDED This manual covers the operating instructions for M843JK marine generator sets M843NK marine generator sets and NL843NK industrial generator sets Fill in the model number of your unit in the blank space provided This will give you a reference whenever service or maintenance is required My Northern Lights generator set MODEL number is Model Numbers Model numbers give the unit s application block model aspiration and RPM M NL 843 J K M
21. ap Maximum Seawater Pump Suction Head Keel Cooler Turbo Tube Length Keel Cooler Head Diameter Keel Cooler Water Hose ID D C Electrical Minimum Battery Capacity Battery Cable Size Starting Voltage Standard A C Electrical Phase Air Intake and Exhaust Air Consumption Maximum Exhaust Backpressure Wet Exhaust Elbow OD Exhaust Gas Volume Exhaust Gas Temperature Fuel System Minimum Suction Line Minimum Return Line Maximum Fuel Pump Suction Head Specific Fuel Consumption at Max Load Approximate Fuel Rate at Max Load Maximum Engine Operating Angle Continuous Operation More than 2 minutes requires use of a remote expansion tank Intermittent Operation Sustained up to two minutes 12 kw 1800 60Hz Inline 3 91 in 1 5 L 4 3 3 x 3 54 in 84 x 90 mm counter clockwise 22 1 5 8 gal 5 5 liter Natural SAE 4 C 107 20 1 HP 700 Ibs 318 kg 36 6 in 1078 mm 19 3 in 490 mm 24 7 in 627 mm 1 1 gal 4 1 liters 3 4 in 19 mm 3 4 in 19 mm 3 4 in 19 mm 790 BTU min 13 3 gal min 50 Itr min 9 0 gal min 34 Itr min 39 in 1M 4 feet 1 2 M 1 in 25 4 mm 1 25 in 31 75 mm 120 Amp Hour 1 12 Volt 1 Phase Std 3 Phase Opt 39 6 cfm 1 13 M m 48 in 1219 mm H O 2 in 51 mm 115 3 3 1022 F 550 C 5 16 3125 in 7 9 mm 5 16 3125 in 7 9 mm 39 in 990 mm 423 Ibs hp hr 1 2 US gal hr Front Down Rear Down 0 0 10 0 35 0
22. e hold the switch in the STOP position until the engine has completely stopped NOTE The rocker switch is used on Series 1 panels only and has a light that glows when the set is running HOUR METER Keeps track of engine running time OIL PRESSURE GAUGE Shows the oil pressure in the engine lubricating system ENGINE TEMPERATURE GAUGE Registers the temperature of the engine coolant D C VOLTMETER OR AMMETER When the engine is stopped the voltmeter indicates the condition of the battery When the engine is running the voltmeter indicates the voltage output of the alternator For Series 4 Control Panels Only T 10 A C VOLTMETER Shows the generator output voltage FREQUENCY METER Hertz The frequency meter indicates alternating current frequency 60 Hz 1800 RPM or 50 Hz 1500 RPM AMMETER VOLTMETER SELECTOR SWITCH Used to check voltage and current of each phase A C AMMETER Shows the generator load on each phase The phase is selected with the Ammeter Selector switch Item 9 O843K 05 03 Control Panels 6 STATUS INDICATOR PANEL Engine monitoring alarms and lamps for monitoring 6 engine functions 7 ALARM LAMP TEST AND RESET BUTTON Press UP to test the indicator lights and press DOWN to reset the alarm 8 AC VOLTAGE ADJUSTMENT RHEOSTAT Voltage has been set at the factory and should only be 7 adjusted factory trained personnel 9 AMMETER SELECTOR SWIT
23. eck the fuel tank level and open any fuel valves 3 Apply electrical load 4 Marine Sets close the sea cock check clean and reassemble the sea strainer and reopen the sea cock STOPPING 5 Marine Sets place the battery switch in the ON position 1 Remove electrical load from the generator set 6 NOTE The battery switch must always be kept 2 Run the engine for a 3 to 5 minute cool down period ON while the engine is running If the switch is 3 Hold the Engine Control switch to the STOP turned OFF while the engine is running the position until the engine comes to a complete stop battery charging regulator could be ruined 4 Marine Sets shut off the seacock fuel valve and battery switch 0843 05 03 8 Operating Procedures SHUTDOWNS AND ALARMS 1 Your unit is fitted with a system to protect it from high water temperature or low oil pressure a Generator sets have shutdown systems to stop the engine They have no warning horns b Other alarms and shutdowns are available as optional equipment NOTE Do not rely on your warning to the exclusion of careful gauge monitoring Watching your gauges can prevent damage to the unit and dangerous power losses 2 Do the following when your warning or shutdown system is activated a Check the temperature gauge Marine sets If above 205 F 96 C shut off the engine immediately Industrial sets If above 230 F 110 C shut off the engine immediately b
24. ections Battery Booster Battery Servicing SP 18 19 BATTERY CARE 1 Check electrolyte level every 50 hours or once per month Add distilled water to manufacturer s recom mended level 2 Batteries cables and cable terminals should be checked and cleaned every 100 hours Clean corrosion with a water and baking soda solution Flush with clean water Tighten terminals and grease them to inhibit corrosion 3 Check the battery condition with a hydrometer every 600 hours P T O 1 The electric clutch P T O does not have any scheduled maintenance points However the equipment the P T O powers may require maintenance Consult the manufacturer of the driven equipment SP20 WINTERIZING OUT OF SERVICE 1 Marine sets a Drain fresh water and seawater cooling systems completely Remember to shut off seacocks before opening drain cocks b Drain water supply lines and wet exhaust line c Loosen the seawater pump cover and drain pump 2 Industrial sets a Drain and flush the radiator and cooling system Leave dry or refill with antifreeze water mixture If refilling start the engine and run to circulate the antifreeze b Fill the fuel tank or add biocide as per manufacturer s instructions Seal the air cleaner inlet exhaust opening crankcase breather pipe and fuel tank vent with plastic bags and tape d Store the set in a dry protected place If unit must be stored outside be sure it is well protected w
25. f above 5 500 ft 1500 meters Use fuel having less that 190 sulphur preferably less that 0 596 The cetane number should be a minimum of 45 DO NOT use these unsuitable grades of fuel a Domestic heating oils all types Class B engine Class D domestic fuels Class E F Gor H industrial or marine fuels ASTM D975 60T No 4 and higher number fuels Storing fuel a Keep dirt scale water and other foreign matter out of fuel b Avoid storing fuel for long periods of time c Fill the fuel tank at the end of each day s operation This will reduce condensation and possible biological contamination d If biological contamination is detected or suspected contact your dealer for assistance CQ Oc Gg FUELS GENERAL SP7 9 FUEL FILTERS 1 Your generator set should have a primary fuel filter installed We recommend the Racor brand of fuel filter water separators a Check the primary fuel filter daily as recommended by the filter manufacturer Empty the collection bowl as necessary b Change the element as often as necessary or every 200 hours c If the bowl fills with water change the primary and secondary element immediately Change secondary fuel filter every 200 hours NOTE The fuel filter on the engine is considered the secondary fuel filter a Remove the spin on filter by turning it counterclockwise with a filter wrench Fill the new cartridge with fuel and install it
26. geable qualified personnel Look completely around engine to make sure that everything is clear before starting Do not operate an engine that isn t in proper working order If an unsafe operating condition is noted tag the set and control panel so others will also know about the problem Provide first aid kits CAUTION This symbol is used throughout this book to alert you to possible danger areas Please take special notice of these sections O843K 05 03 3 NOORON Non Service Side gt DC Circuit Breaker AC Circuit Breaker for AVR Fuel Filter Air Filter inside Manifold Intake Manifold Fuel Lift Pump Oil Fill 2 8 9 10 11 12 13 14 Figure 2 M843JK M843NK service and non service views Crankcase Vent 15 Fuel Injector 16 Coolant Fill 17 Heat Exchanger End Cap 18 Injection Pump 19 Seawater Pump 20 Freshwater Block Drain 21 Marine Generator Component Locations Fuel Inlet amp Return Oil Filter Oil Dipstick Oil Drain Control Panel Plug In Generator Set Plate Expansion Tank 22 23 24 25 26 Wet Exhaust Elbow Junction Box Starter Vibration Mount DC Alternator O843K 05 03 4 Industrial Generator Set Component Locations lt Service Side Non Service Side gt 8 0 Figure 3 NL843NK service and non service views 1 DC Alternator 8 Lube Oil Drain 16 Fuel Inlet and Return 2 Exhaust Outlet 9 AC
27. h Hull Diameter Sea Water Pump Inlet Hose ID Minimum Sea Water Discharge Heat Rejection to Jacket Coolant Fresh Water Pump Capacity Seawater Pump Cap Maximum Seawater Pump Suction Head Keel Cooler TurboTube Length Keel Cooler Head Diameter Keel Cooler Water Hose ID D C Electrical Minimum Battery Capacity Battery Cable Size Starting Voltage Standard A C Electrical Phase Air Intake and Exhaust Air Consumption Maximum Exhaust Backpressure Wet Exhaust Elbow OD Exhaust Gas Volume Exhaust Gas Temperature Fuel System Minimum Suction Line Minimum Return Line Maximum Fuel Pump Suction Head Specific Fuel Consumption at Max Load Approximate Fuel Rate at Max Load Maximum Engine Operating Angle Continuous Operation More than 2 minutes requires use of a remote expansion tank Intermittent Operation Sustained up to two minutes M843JK Data 10 kW 1800 60Hz Inline 3 81in 1 33 liters 4 3 3 x 3 2 in 84 x 80 mm counter clockwise 23 1 6 0 gal 5 7 liter Natural SAE 4 C 107 17 5 HP 662 Ibs 300 kg 36 6 in 1078 mm 19 3 in 490 mm 24 2 in 616 mm 1 1 gal 4 1 liter 3 4 in 19 mm 3 4 in 19 mm 3 4 in 19 mm 703 BTU min 13 3 gpm 50 Ipm 9 0 gpm 34 lpm 39 in 1M 4 feet 1 2 M 1 in 25 4 mm 1 25 in 31 75 mm 120 Amp Hour 1 12 Volt 1 Phase Std 3 Phase Opt 35 2 cfm 1 0 M m 48 in 1219 mm H O 2 in 51 mm 102 2 9 M3 m 1022 F 550 C 5
28. hen servicing the D C alternator Never test with a screwdriver etc against any terminal to see if it emits sparks Do not polarize the alternator or regulator A D C circuit breaker protects your control panel and wiring harness It is located in the side of the generator junction box O843K 05 03 GLOW PLUGS Each cylinder is supplied with a glow plug which serves to heat the combustion chamber To check the glow plugs loosen the current carrying flat wire between the plus poles of the glow plugs Figure 18 Connect a D C test bulb between the plus pole of the battery and the plus pole of the glow plug If the bulb lights up the glow plug is functioning properly Check all glow plugs and replace any faulty ones Glow Plugs 7 Y TM i BOOSTER BATTERIES CAUTION Battery gas can explode Keep all flames and sparks away from batteries 1 Before changing or using booster batteries check battery electrolyte level Add distilled water if necessary 2 Booster and main batteries must have the same voltage rating 3 First connect positive 4 terminal of booster battery to positive terminal of main battery Then connect negative terminal of booster battery to ground on the engine block see Figure 19 4 Remove booster battery after starting engine 5 Sealed batteries See manufacturer charging and booster instructions Figure 19 Battery conn
29. ith a cover 3 Marine and Industrial sets a Change the crankcase oil and filter b Loosen the alternator belt c Disconnect and clean battery Remove to warm storage place if possible d Clean outside of unit Paint any scratched or chipped surfaces Put corrosion preventative on all exposed metal surfaces SP21 EXHAUST ELBOW Look for external corrosion and signs of exhaust leakage O843K 05 03 19 DC ELECTRICAL SYSTEM PROBLEM Battery Will Not Charge Starter Inoperative Starter Cranks Slowly Entire Electrical System Does Not Function POSSIBLE CAUSE Loose or corroded connections Sulfated or worn out batteries Loose or defective alternator belt Check DC circuit breaker Loose or corroded connections Low battery output Defective electrical system ground wire Low battery output Check specific gravity of each battery Check electrolyte level of each battery Crankcase oil too heavy Loose or corroded connections Check DC circuit breaker Faulty connection Sulfated or worn out batteries Troubleshooting RECOMMENDATION S Clean and tighten battery connections Check specific gravity of each battery Check electrolyte level of each battery Adjust belt tension Replace belt f the breaker is tripped reset it Clean and tighten loose battery and harness plug connection Check specific gravity of each battery Check electrolyte level
30. l m m E qo 3NION3 35 lt T s 101 lt 3592 anh ae 3LIHM 25 303 Soma 019 K QNhOM9 3Svo 3idund LE 3Wuna AVIY T suma 8 0 M313 S nOH aas lt 1H9l ve 3HHM ou yyy 08 018 29 m S wolv3IONI nd 3ldafid xi Jui 18 OF K 9015 YOLVNYALTY T3871 OF or uS oF LB d Daana ca 98 A389 lt 66 4 US oam Av13H 3 2 uw 1nHS t i s lt lt fas HOLIMS T38 ROTUK i P z 337MOTI3A SSVd 8 001 038 Oif 001 038 011 52 2 HOLIMS NMOGLNHS nag JOMINOO 3NI9N3 MAZ L 9OAZ L 79018 INNI KE lt lt zo T 1 HOV3 4 S V qay lla UP No 8 5 JNION3 lt QMVO8 NOISN31X3 13 TOHLNO9 O843K 05 03 27 0843 05 03 28
31. lled fuel escapes Then tighten the connection Do each 2 Loosen bleed bolt A Figure 9 on top of the filter line one at a time Pump hand primer on fuel lift pump until pure 5 After the engine has started use a piece of cardboard fuel no bubbles escapes from bleed bolt A to look for fuel leaks Tighten bleed screw O843K 05 03 15 Servicing Figure 11 Remove delivery lines Figure 13 Remove return line nuts Figure 17 Reinstall injector Torque to proper tightness O843K 05 03 16 SP11 INJECTOR SERVICE l Injectors should be checked every 600 hours Check should be made by a Northern Lights dealer or local injection repair station CAUTION Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping diesel fuel see a doctor at once 2 Injector removal a Clean loose dirt from around the injectors and the fuel lines Relieve high pressure in the fuel lines by loosening the delivery line flare nuts at each injector Figure 10 Remove delivery lines by disconnecting from injectors and injection pump Figure 11 Remove all lines as an assembly do not remove the spacers Cover the ends of the lines the injector inlets and injection pump outlets to keep dirt out Figure 12 Remove the return line retaining bolts Figure 13
32. mp SP15 Check and clean heat exchanger marine only SERVICE 50 100 200 600 2400 PAGE OPERATION DAILY Hours Hours Hours Hours Hours ENGINE SP1 Check oil level SP2 Change engine oil SP3 Change lube oil filters SP4 Check air cleaner SP5 Check V belt tension SP6 Check valve clearances FUEL SYSTEM SP7 Check primary filter Racor SP8 Change primary filter element Racor SP9 Change secondary fuel filter SP10 Bleed the fuel system SP11 Check injectors SP12 Check fuel injection pump e COOLING SYSTEM SP13 Check cooling water level SP14 Check and flush cooling system SP15 Check and clean heat exchanger Marine e SP16 Check and clean radiator fins Industrial SP17 Change impeller in raw water pump SP21 Inspect condition of exhaust elbow ELECTRICAL SYSTEM SP18 Check electrolyte level in batteries SP19 19 Check condition of batteries with hydrometer DRIVEN EQUIPMENT SP20 19 Clutch and PTO service M843NK only 2 OUT OF SERVICE SP21 19 Winterizing or out of service 3 1 Perform all maintenance once a year even if hour level has not been reached 2 Consult manufacturer s maintenance schedule note on chart 3 Whenever necessary 4 More often if necessary 5 After first 50 hours 0843 05 03 10 0 unsere 50 HOURS SP
33. n the reverse direction of the airflow SP14 COOLING SYSTEM FLUSHING SP17 RAW WATER PUMP Marine 1 Change the seawater pump impeller every 600 hours or as needed Remove the pump end cover Pry out the impeller using needle nose pliers or two screwdrivers Be sure you remove all pieces of failed impeller NOTE Place some kind of protection under the screwdrivers in order not to damage the pump housing If the impeller has broken into pieces remove front heat exchanger end cover and inspect for impeller pieces Clean inlet to heat exchanger bundle and reassemble Clean the inside of the housing Press in the new impeller and place the sealing washers in the outer end of the impeller center if this has not already been done Replace the cover using a new gasket NOTE Make sure that there is always an extra impeller and cover gasket in reserve on board GENERATOR ENDS The maintenance and operation recommendations for the generator end are in a separate Owner s Manual If you do not have one of these manuals contact your local Northern Lights dealer ELECTRICAL SYSTEM GENERAL Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running Regulator damage can result Do NOT reverse the polarity of battery cables when installing the battery If welding on the unit disconnect the regulator and battery Isolate the leads Disconnect the battery cables w
34. or faulty injection nozzles RECOMMENDATION S See starting section of this manual Take special note of Bypass Switch operation Check level of fuel in fuel tank Check electrolyte level and condition Clean and tighten all battery connections Use oil of proper viscosity Consult fuel supplier and use proper type of fuel for operating condition Drain flush fill and bleed system Clean or replace filter element Replace filter element Have your dealer check injection nozzles Remove and check thermostat Clean or replace filter element Replace secondary filter element Drain flush fill and bleed system Have your dealer check injection nozzles Inspect clamps and hoses on suction side of fuel pump for air leak Consult fuel supplier and use proper type of fuel for operating condition Service air cleaner Clean or replace filter element Replace filter element Consult fuel supplier and use proper type of fuel for operating conditions See Engine Overheats in next category Remove and check thermostat Reset valves Best done by dealer Replace injectors Best done by dealer See your local dealer O843K 05 03 21 ENGINE PROBLEM Engine Overheats Engine Knocks High Fuel Consumption Below Normal Engine Temperature Low Oil Pressure High Oil Consumption POSSIBLE CAUSE Low coolant level Keel cooling
35. rain cock Remove hose from bottom of heat exchanger tank c Pour clean water into expansion tank until water coming from drains is free of discoloration and sediment Let water drain completely Close drains and refill with recommended mixture Industrial sets Remove radiator cap and open drain cocks on radiator and engine block Pour clean water into radiator until water coming from radiator is clear of discoloration Close the radiator drain and continue flushing until water from engine drain is clear Open all drain cocks and drain completely Close drain cock and refill with recommended coolant mixture Clean fins on radiator Coolant Specifications marine and industrial Use 50 distilled water 5096 ethylene glycol antifreeze mix Antifreeze mixture is recommended as a good year round coolant Check hoses and connections and repair any leakage SP15 HEAT EXCHANGER Marine 1 Clean the heat exchanger core once a year or after 2400 hours of operation Drain expansion tank and heat exchanger Remove heat exchanger end covers and remove core Clean the inside of exchanger core tubes using a metal rod Flush inspect and clean again if necessary Reassemble Fill the cooling system start the engine and check for leaks SP16 CLEAN RADIATOR Industrial 1 2 Remove debris from radiator fins daily In very dusty applications clean the radiator with compressed air or steam cleaner every 100 hours Clean i
36. rn farther Overtightening can do damage to filter housing Fill engine with recommended oil Start engine and check for leakage Stop engine wait 3 minutes and check oil level Add additional oil if necessary Oil filter part number is 843JK and 843 24 03100 O843K 05 03 5 4 AIR CLEANER 1 Inspect air cleaner every 200 hours In dusty conditions check more often 2 Marine sets if dirty wash element in soapy water Rinse and dry thoroughly before re installing Replace if necessary Part numbers are M843JK and M843NK 24 23100 3 Industrial sets the element cannot be cleaned Replace it when necessary Part number is NL843NK 7314531127 4 NOTE Make absolutely sure no impurities enter the engine while changing the element Do NOT run the engine with the air cleaner removed SP5 V BELTS 1 Check the tension and wear on the V belt after every 50 hours 2 Use your thumb to press on the belt at the midpoint between the crankshaft and alternator pulleys The tension is correct if the belt can be depressed about 3 16 in 5 mm RETIGHTENING CYLINDER HEAD BOLTS 1 Tighten bolts when the engine is cold 2 Loosen the nuts and remove rocker arm cover 3 Tighten head bolts with a torque wrench in the order shown in figures below Tighten bolts evenly in 2 or 3 passes ending at the specified torque in final pass 843JK amp 843NK 60 64 ft Ibs 9 0 9 5 kg m Figure 7
37. roper level Drain and fill crankcase with correct oil Replace filter Oil consumption decreases after break in Use proper viscosity oil Check for leaks in lines around gaskets and drain plug If you cannot correct problems with these procedures see your Northern Lights dealer O843K 05 03 22 Troubleshooting ENGINE PROBLEM POSSIBLE CAUSE RECOMMENDATION S Engine Emits Black Clogged or dirty air cleaner Service air cleaner or Gray Exhaust Smoke Defective muffler Have dealer check back pressure back pressure too high Improper fuel Use correct fuel for temperature Injection nozzles dirty See your dealer Engine out of time See your dealer Engine Emits Improper fuel Use correct fuel for temperature White Cold engine Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Engine out of time See your dealer If you cannot correct problems with these procedures see your Northern Lights dealer O843K 05 03 23 Kilowatt Rating Prime Rated RPM Frequency General Information Cylinders Displacement Cycles Bore x Stroke Rotation Facing Flywheel Compression Ratio Total Engine Oil Capacity including Oil Filter Aspiration Flywheel Housing Size Flywheel Drive Size Rated Flywheel HP Dry Weight w Heat Exchanger 1 Length Width Height Cooling System Approx Cooling Capacity HE Minimum Throug
38. ter pump This will prevent the muffler from filling seat the rings with water and backfilling the exhaust line and engine Once the engine starts shut it off immediately and BEFORE STARTING re install the impeller Re start the engine and check the exhaust overboard outlet for gushes of water 1 Check the water level by removing the pressure cap from the expansion tank or radiator In order to OPERATING give the cooling water an opportunity to expand the level should be about 1 in 2 5 cm below the filler 1 Units with Series 3 and Series 4 Control Panels cap sealing surface when the engine is cold check gauges often Oil pressure must be above 15 PSI The D C voltmeter should read between 11 and CAUTION Use protective clothing and open 15 volts at 80 F 25 C ambient temperature The the filler cap carefully when the engine is warm water temperature gauge on Marine sets must be to prevent burns below 200 F 94 on Industrial units the water temperature gauge must be below 225 F 107 C 2 Check the oil level in the crankcase with the Check the A C voltage and frequency meters Series dipstick The oil level must be in the waffled area on 4 panel If the gauges deviate from normal levels the stick Never allow the level to go below this area shut down the generator set and investigate Always add the same viscosity of oil as is already in 2 Let the unit run unloaded for a three to five minute the crankcase warm up period Ch
39. tubes have been painted marine Cooling system needs flushing Defective thermostat Defective temperature gauge Water pump impeller worn broken Insufficient oil Injection pump out of time Below normal engine temperature Engine overheating Improper type of fuel Clogged or dirty air cleaner Improper valve clearance Injection nozzles dirty Injection pump out of time Engine not at proper temperature Thermostat not working properly Temperature gauge not working properly Low oil level Improper type of oil Partially plugged oil filter Break in period Crankcase oil too light Oil leaks Troubleshooting RECOMMENDATION S Hill tank or radiator to proper level Check hoses for loose connections and leaks Remove paint from tubes Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace gauge if necessary Check impeller and replace if necessary Call your dealer Call your dealer Check your thermostats Check water temperature to see if temperature gauge is working properly See Engine Overheating section Use correct fuel for temperature Service air cleaner See your dealer See your dealer See your dealer Check your thermostats Check water temperature with thermometer and replace gauge if necessary Check thermostat Check water temperature with thermometer Fill crankcase to p
40. water pump impeller amp gaskets marine only Glow plug Injector and washer 3 If your set is operating a long distance from a servicing dealer add the following a Complete set of injectors b Copper washers for injector change c Complete set of glow plugs d Fuel lift pump mo coc 0843 05 03 9 DAILY SP1 Check oil level in engine SP7 Check primary fuel filter SP13 Check cooling water level Check sea strainer marine only Check raw water pump for leaks AFTER FIRST 50 HOURS SP2 3 Change engine oil and filter SP5 Check V belt tension SP6 Adjust valves SP18 Check electrolyte in batteries Retighten head bolts see page 11 EVERY 50 HOURS Servicing Schedule Chart The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set More detailed coverage of each Service Point SP is listed on the page noted in the column EVERY 100 HOURS SP16 Check and clean radiator industrial only EVERY 200 HOURS SP2 3 Change engine oil and filter SP4 Check air cleaner SP8 Change primary fuel filter element SP9 Change secondary fuel filter EVERY 600 HOURS SP6 Check valve clearances SP11 Check injectors SP14 Check and flush cooling system SP17 Change impeller marine only SP19 Check state of charge of batteries SP5 Check V belt tension SP18 Check electrolyte in batteries EVERY 2400 HOURS SP12 Check fuel injection pu
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